brake CHRYSLER VOYAGER 2004 Service Manual

(10) Install the coupling onto the intermediate
shaft and install the pinch bolt. Tighten the pinch
bolt to 28 N´m (250 in. lbs.).
(11) Install the cable from the bracket on the col-
umn, then install the pinch side clips.
(12) Reconnect the shift cable at the lever.
(13) Reconnect the wiring harness connectors to
the clockspring, multi-function switch, halo lamp,
SKIM module, ignition switch and BTSI solenoid.
(14) Install the steering wheel (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
INSTALLATION).
(15) Install the vibration damper weight.
(16) Install the steering wheel retaining nut.
Tighten the nut to 61 N´m (45 ft. lbs.)
(17) Install the airbag (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - INSTALLATION).
(18) Install the knee blocker reinforcement (Refer
to 23 - BODY/INSTRUMENT PANEL/KNEE
BLOCKER - INSTALLATION).
(19) Install the parking brake handle link.
(20) Install the knee blocker (Refer to 23 - BODY/
INSTRUMENT PANEL/STEERING COLUMN
OPENING COVER - INSTALLATION).
(21) Install the cluster trim bezel (Refer to 23 -
BODY/INSTRUMENT PANEL/CLUSTER BEZEL -
INSTALLATION).
(22) Install the upper shroud (Refer to 19 -
STEERING/COLUMN/LOWER SHROUD - INSTAL-
LATION).
(23) Install the traction off switch.
(24) Install the lower shroud.
SPECIFICATIONS
COLUMN TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Driver Airbag Attaching Bolts 10 Ð 90
Steering Column Coupling
Pinch Bolt28 Ð 250
Steering Column Mounting
Nuts12 Ð 105
Steering Wheel Retaining
Nut61 45 Ð
IGNITION SWITCH
REMOVAL
The ignition switch attaches to the lock cylinder
housing on the end opposite the lock cylinder (Fig. 7).
For ignition switch terminal and circuit identifica-
tion, refer to the appropriate wiring information. The
wiring information includes wiring diagrams, proper
wire and connector repair procedures, further details
on wire harness routing and retention, as well as
pin-out and location views for the various wire har-
ness connectors, splices and grounds.
(1) Disconnect negative cable from battery.
(2) Remove steering column cover retaining screws
(Fig. 8).
Fig. 7 Ignition SwitchÐViewed From Below Column
1 - IGNITION SWITCH
2 - LOCK CYLINDER HOUSING
3 - RETAINING TABS
Fig. 8 Steering Column Cover
1 - SCREWS
2 - STEERING COLUMN COVER
19 - 14 COLUMNRS
COLUMN (Continued)

(3) Remove parking brake release cable from han-
dle (Fig. 9).
(4) Remove screws holding steering column
shrouds (Fig. 10)and remove lower shroud.(5) Place key cylinder in RUN position. Depress
lock cylinder retaining tab and remove key cylinder
(Fig. 11).
(6) Remove ignition switch mounting screw (Fig.
12) with a #10 Torxttamper proof bit.
(7) Depress retaining tab (Fig. 8) or (Fig. 13) and
gently pry ignition switch from steering column (Fig.
14).
(8) Disconnect electrical connectors from ignition
switch and remove switch (Fig. 15).
Fig. 9 Parking Brake Release Cable
1 - PARKING BRAKE CABLE
2 - PARKING BRAKE HANDLE
Fig. 10 Steering Column Shroud Screws
1 - STEERING WHEEL
2 - SCREWS
3 - LOWER STEERING COLUMN SHROUD
Fig. 11 Lock Cylinder Retaining Tab
1 - IGNITION SWITCH
2 - RETAINING TAB
Fig. 12 Ignition Switch Mounting Screw
1 - MOUNTING SCREW
2 - IGNITION SWITCH
RSCOLUMN19-15
IGNITION SWITCH (Continued)

LOCK CYLINDER HOUSING
DESCRIPTION - IGNITION INTERLOCK
All vehicles equipped with automatic transaxles
have an interlock system. The system prevents shift-
ing the vehicle out of Park unless the ignition lock
cylinder is in the Unlock, Run or Start position. In
addition, the operator cannot rotate the key to the
lock position unless the shifter is in the park posi-
tion. On vehicles equipped with floor shift refer to
the - Transaxle for Automatic Transmission Shifter/
Ignition Interlock.
REMOVAL
NOTE: Before proceeding, review all Steering Col-
umn and Airbag Warnings and Cautions. (Refer to
19 - STEERING/COLUMN - WARNING)(Refer to 8 -
ELECTRICAL/RESTRAINTS - WARNING)
(1) Remove battery ground cable terminal from
battery negative post and isolate.
(2) Under instrument panel, remove silencer panel
below lower steering column cover.
(3) Remove screws securing lower steering column
cover/knee blocker, then remove it (Fig. 17).
(4) Disconnect parking brake release link at
release handle.
(5) Compress tabs on sides of data link diagnostic
connector and remove it from knee blocker reinforce-
ment plate.(6) Remove screws securing knee blocker reinforce-
ment plate in place, then remove reinforcement plate
(Fig. 17).
(7) Remove the upper and lower column shrouds.
(Refer to 19 - STEERING/COLUMN/LOWER
SHROUD - REMOVAL)
(8) Unsnap the trim bezel on the instrument panel
between the instrument cluster and the steering col-
umn.
(9) Remove the 2 screws securing the steering col-
umn fixed shroud to the steering column (Fig. 18),
then remove the shroud.
(10) Remove the two screws holding the metal
cover in place below the shifter/ignition interlock
linkage (Fig. 19), then remove the cover.
Fig. 17 Lower Steering Column Cover And
Reinforcement
1 - INSTRUMENT PANEL
2 - REINFORCEMENT PLATE
3 - LOWER STEERING COLUMN COVER/KNEE BLOCKER
Fig. 18 Fixed Shroud Mounting
1 - SCREWS
2 - SHROUD
Fig. 19 Cover Removal/Installation
1 - IGNITION SWITCH
2 - SCREW
3 - COVER
RSCOLUMN19-17

retaining tab on the lever with the ramp on the link
(Fig. 20), then pushing the two together.
(12) Install the metal cover in place below the
shifter/ignition interlock linkage using the two
screws (Fig. 19).
(13) Install the steering column fixed shroud on
the steering column (Fig. 18) using its 2 mounting
screws.
(14) Install the trim bezel on the instrument panel
above the steering column. The trim bezel is
mounted to the instrument panel using 2 screws (one
on each side of the column) and retaining clips.
(15) Install the lower and upper steering column
shrouds. (Refer to 19 - STEERING/COLUMN/
LOWER SHROUD - INSTALLATION)
(16) Install the knee blocker reinforcement plate
(Fig. 17).
(17) Connect the parking brake release link to the
release handle.
(18) Install the data link diagnostic connector to
the mounting hole in the reinforcement plate.
(19) Install the lower steering column cover/knee
blocker (Fig. 17).
(20) Connect the negative (ground) cable to the
battery terminal.
KEY/LOCK CYLINDER
DESCRIPTION
The lock cylinder is inserted in the end of the
housing opposite the ignition switch.
OPERATION
The ignition key rotates the cylinder to 5 different
detents (Fig. 28) :
²Accessory
²Off (lock)
²Unlock
²On/Run
²Start
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove steering column cover retaining
screws.
(3) Remove screws holding steering column
shrouds and remove lower shroud.
(4) Place key cylinder in RUN position. Depress
lock cylinder retaining tab on the bottom of the lock
housing and remove key cylinder.
INSTALLATION
(1) Install key in lock cylinder. Turn key to run
position (retaining tab on lock cylinder can be
depressed).
(2) The shaft at the end of the lock cylinder aligns
with the socket in the end of the housing. To align
the socket with the lock cylinder, ensure the socket is
in the Run position (Fig. 29) .
(3) Align the lock cylinder with the grooves in the
housing. Slide the lock cylinder into the housing
until the tab sticks through the opening in the hous-
ing.
(4) Turn the key to the Off position. Remove the
key.
(5) Install lower steering column shroud.
(6) Install steering column cover.
(7) Connect negative cable to battery.
Fig. 28 Ignition Lock Cylinder Detents
Fig. 29 Socket in Lock Cylinder Housing
1 - LOCK CYLINDER HOUSING
2 - SOCKET
19 - 20 COLUMNRS
LOCK CYLINDER HOUSING (Continued)

INSTALLATION
(1) Install gearshift boot to console and secure
with three (3) retaining clips (Fig. 130).
(2) Install gearshift knob (Fig. 129). Orient shift
pattern
1¤4-turn clockwise, press down, and rotate1¤4-
turn counter-clockwise.
(3) Secure gearshift boot to base of knob.
GEARSHIFT CABLE -
CROSSOVER
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove gearshift knob by pushing down and
rotating
1¤4-turn clock-wise (Fig. 131).
(3) Remove gearshift boot from center console by
disengaging at three (3) retaining clips (Fig. 132).
(4) Apply park brake to allow park brake handle to
clear center console upon removal.
(5) Remove two (2) cupholder bottom plugs (Fig.
133).
Fig. 131 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 132 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 133 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
RST850 MANUAL TRANSAXLE21-73
GEARSHIFT BOOT (Continued)

(4) Apply park brake to allow park brake handle to
clear center console upon removal.
(5) Remove two (2) cupholder bottom plugs (Fig.
157).
(6) Remove four (4) center console-to-gearshift
mechanism screws. Remove console assembly (Fig.
158).(7) Loosen crossover cable adjustment screw (Fig.
159).
(8) Rock gearshift lever back and forth between
1±2 and 5±R planes. Release lever, allowing shifter
spring to return lever to the neutral position in the
3±4 plane. Place gearshift lever in the 3rd gear posi-
tion.
(9) Torque crossover lever adjustment screw to 8
N´m (70 in. lbs.).No load should be applied to
the shifter lever in any direction (hands off)
while tightening screw.
(10) Verify gearshift lever travel through all gear
ranges with engine off (not running).
(11) Install center console assembly (Fig. 158).
Install and torque center console-to-gearshift mecha-
nism screws to 5 N´m (45 in. lbs.).
(12) Install cupholder plugs (Fig. 157).
(13) Install gearshift boot to console (Fig. 156).
Secure boot to console with three (3) retainer clips.
(14) Install gearshift knob to gearshift lever (Fig.
155). Orient shift pattern on knob
1¤4-turn clockwise,
push down and rotate1¤4-turn counter-clockwise and
release. Secure boot to knob.
(15) Connect battery negative cable.
Fig. 157 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 158 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
Fig. 159 Crossover Cable Adjustment Screw
1 - CROSSOVER CABLE
2 - ADJUSTMENT SCREW
21 - 80 T850 MANUAL TRANSAXLERS
GEARSHIFT CABLE - CROSSOVER (Continued)

GEARSHIFT CABLE -
SELECTOR
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove gearshift knob by pushing down and
rotating
1¤4-turn clock-wise (Fig. 160).
(3) Remove gearshift boot from center console by
disengaging at three (3) retaining clips (Fig. 161).(4) Apply park brake to allow park brake handle to
clear center console upon removal.
(5) Remove two (2) cupholder bottom plugs (Fig.
162).
(6) Remove four (4) center console-to-gearshift
mechanism screws. Remove console assembly (Fig.
163).
Fig. 160 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 161 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 162 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 163 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
RST850 MANUAL TRANSAXLE21-81

(3) Remove gearshift boot from center console by
disengaging at three (3) retaining clips (Fig. 186).
(4) Apply park brake to allow park brake handle to
clear center console upon removal.
(5) Remove two (2) cupholder bottom plugs (Fig.
187).(6) Remove four (4) center console-to-gearshift
mechanism screws. Remove console assembly (Fig.
188).
(7) Remove center console support bracket (Fig.
189).
Fig. 186 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 187 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 188 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
Fig. 189 Center Console Support Bracket
1 - BRACKET
2 - SCREW
3 - GEARSHIFT MECHANISM
21 - 88 T850 MANUAL TRANSAXLERS
GEARSHIFT MECHANISM (Continued)

(8) Remove crossover cable retainer clip (Fig. 190).
(9) Remove crossover cable from gearshift mecha-
nism (Fig. 191).
(10) Remove selector cable retainer clip (Fig. 192).
(11) Remove selector cable from gearshift mecha-
nism (Fig. 193).
(12) Remove four (4) gearshift mechanism-to-park
brake bracket nuts. Remove gearshift mechanism
from bracket (Fig. 194).
INSTALLATION
(1) Install gearshift mechanism to park brake
bracket (Fig. 195). Install and torque nuts to 12 N´m
(108 in. lbs.).
(2) Install selector cable to gearshift mechanism
(Fig. 196). Install retainer clip (Fig. 197).
Fig. 190 Crossover Cable Retainer Clip
1 - RETAINER CLIP
2 - CROSSOVER CABLE
Fig. 191 Crossover Cable at Gearshift Mechanism
1 - GEARSHIFT MECHANISM
2 - CROSSOVER CABLE
Fig. 192 Selector Cable Retainer Clip
1 - RETAINER CLIP
Fig. 193 Selector Cable at Gearshift Mechanism
1 - GEARSHIFT MECHANISM
2 - SELECTOR CABLE
RST850 MANUAL TRANSAXLE21-89
GEARSHIFT MECHANISM (Continued)

(3) Install crossover cable to gearshift mechanism
(Fig. 198). Install retainer clip (Fig. 199).
Fig. 194 Gearshift Mechanism Removal/Installation
(RHD Shown Ð LHD Typical)
1 - GEARSHIFT MECHANISM
2 - PARK BRAKE BRACKET
3 - NUT (4)
Fig. 195 Gearshift Mechanism Removal/Installation
(RHD Shown Ð LHD Typical)
1 - GEARSHIFT MECHANISM
2 - PARK BRAKE BRACKET
3 - NUT (4)
Fig. 196 Selector Cable at Gearshift Mechanism
1 - GEARSHIFT MECHANISM
2 - SELECTOR CABLE
Fig. 197 Selector Cable Retainer Clip
1 - RETAINER CLIP
21 - 90 T850 MANUAL TRANSAXLERS
GEARSHIFT MECHANISM (Continued)